Hi I'm about to buy manual trans. to swap into my 85 300d, so what parts I need from 80 240 for successful conversation? Thanks

Just off the top of my head, you'll need the transmission and clutch assembly, flywheel, clutch pedal, pushrod, and master and slave cylinders, the 240D brake reservoir, the hose from the reservoir to the MC, along with the line from the MC to the slave. The transmission mount will need to be modified, or I'm told one from an automatic 240D will work. The driveshaft from the 240D will need to be shortened. Assuming your '85 still has the '85 engine, you'll need the smaller 34 mm pilot bearing, and will probably need to prep the hole in the back of the crank. If you can't find a bearing, you can probably have a bushing machined for not too much money.

I'm probably leaving something out. There have been several detailed threads on auto to manual swaps. Search function will help you find them.

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Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

As Skippy said. The 240D Reservoir is the same as all MB are. there is a Nipple on the side of all of them, snip off the ebd and run the supply hose to the master Cylinder.

I would use a new MC and Slave Cylinder than to install used one.

The 85 engine Crank hole is 34mm and every other MB Diesel is 35mm. so there is no bearing made that will fit.

I just went through this on a engine Iam installing. My machinist buddy took a measurement of the hole and then the bearing. there was 7 thousands difference. he used a belt Sander, and holding the bearing in his fingers, and using his Thumbs of the outer ring to put a slight drag as it turned, took it down. Took quite a few tries back and forth to finally get it right. be sure to have a few bearings in case there is a screw up.

I would not try to hone out the Crank hole, could be done, but if too much.......

Use a 240D Automatic X mount, one off a 280E is the same. you will have to move the mount back to the next set of holes. Its a wider mount and uses 4 holes.

On the Shift Rods, measure twice, and cut once. On the screw on ends, notice how far they screw on. Unscrew them and mount onto the shifter. mount the Rods on the transmission. Hold the screw on end level and lay the Rod on top of it. then mark the rod with a felt pen or?? where it lines up. usually about the middle of the open hole.

Thread the ends and screw it together. You will have to tweek and bend the rods to get them to line up and not rub.

On the bottom of the shifter are 2 V shaped pieces on either side of the 3 levers. Place a Drill Bit or Nail etc... of the proper size. This lines then up in the neutral position.

Remove the NSS wiring that goes into the cabin and unplug it. It has 2 purple wires for start and the other two BLK/yel ? are for the back up lights. the plug from the shifter plugs into this plug where you unplugged the NSS.

I removed the grommet the NSS went through, washed it up/degreased, installed and filled it with RTV.

There is a plug under the fuel feed peddle the Clutch line goes through.

Its all pretty much plug and play.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

what would be a decent price to pay for all the convertion parts? trans flywheel drive peddles, the whole 9 yards?

I bought a complete 240D for $600, sold the engine cheap to a buddy and the carcass to PnP for (IIRC) $175. So I have about $300 or so in mine. No idea if that's a good deal or not but it gives you EVERYTHING you'll need including shifter, rods, etc. My next job is installing the shifter and sorting out the rods.

I'm using the S-10 master cylinder so I'm no help on the hydraulic part of it. I have the 300SD and 240D driveshafts free for the taking - if you'll take 'em. No idea of their condition other than they are intact.

Dan

Definitely get new master and slave cylinders!!! Both of mine blew out when I was like 300 miles from home about a week after finishing the swap. Luckily I managed to figure out how to shift without the clutch

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1982 300D Turbodiesel, daily driver. Mods so far: Fram 8038 paper filter, 4 brake light mod, Gen II w126 (front) rotors/calipers, boost turned up to 12lbs, non-egr manifolds, water/methanol injection, 4-speed manual
1980 300SD Turbodiesel, project car, nearly ready to hit the street

1974 240D, New paint

I bought a whole 240D for $480, drove it for three years, and then cannibalized it for the transmission. I sold what was left over to some guy from Fallon for $200.

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

I think MagicBus has the swap parts if you want.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

Pulling the parts from PNP probably 3 - $400.00.

Sachs Clutch Disk $150
Pressure plate around $90
Pilot Bearing, seen this bearing from $1.50 - $9.00
MC $60.00
Release bearing, $40 - $50
Slave $40
Clutch Line $75 if you need one and can`t salvage it.
Clips on Shift Rods $4 X 6. You might be able to salvage the used ones.

Then you still have to match balance the FW and maybe resurface it. there is $100
The Driveline will have to be shortened, welded and balanced


That`s a ball Park figure.

To do a swap you are looking at a healthy $1000.00. have a shop do it and the cost go`s up.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

I bought my clutch kit from a prominent on-line parts source and it was less than that (about $285) - also turned out to be a Sachs. That had the disc, pressure plate, throw-out bearing, and alignment tool (which fit a bit too tight on the clutch splines). I know the guys at our local AAMCO shop and they turned the flywheel for free - I did have them rebuild my trans in the Dodge Diesel truck to the tune of $3K so maybe that was a customer "thank you".

When you have the flywheel turned be sure the shop knows about stepped flywheels. The pressure plate (also called a "clutch cover" in some parts of the country) bolts to a recess in the flywheel and that recess has to be turned down the same amount as the clutch surface or the clutch won't travel properly. Most pressure plates bolt to the same surface as the clutch surface so that's not an issue but it matters on the Benz. BTW - lots of heavy equipment (tractors, etc.) are made like this so if your local machine shop can't handle it go to your farm equipment dealer.

Dan